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A driven gear in the gear box of an aircraft engine fractured after a 40 h test run. The driving gear and gear shaft were also damaged. Based on the results of fractography, chemical analysis, metallography, and hardness testing, the fracture was caused by a fatigue crack initiating at the corner of the inner rim near an inclusion. The report recommends the use of a cleaner material and more carefully controlling case hardening process.

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Failure of a Gear in an Aircraft Engine, Failure Analysis of Engineering Structures: Methodology and Case Histories, By V. Ramachandran, A.C. Raghuram, R.V. Krishnan, S.K. Bhaumik, ASM International, 2005, p 177–179,

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